Electrode Active Material and Method of Making The Same

ABSTRACT

The invention provides an electrochemical cell which includes a first electrode and a second electrode which is a counter electrode to said first electrode, and an electrolyte material interposed there between. The first electrode includes an alkali metal phosphorous compound doped with an element having a valence state greater than that of the alkali metal.

This application is a continuation of U.S. Ser. No. 11/291,298, filedDec. 1, 2005, which is a divisional of U.S. Ser. No. 10/741,257, filedDec. 19, 2003, now issued as U.S. Pat. No. 7,718,317, which claimspriority to U.S. Ser. No. 60/435,144 filed Dec. 19, 2002.

FIELD OF THE INVENTION

This invention relates to improved electrode active materials, methodsfor making such improved active materials, and electrochemical cellsemploying such improved active materials.

BACKGROUND OF THE INVENTION

A battery consists of one or more electrochemical cells, wherein eachcell typically includes a positive electrode, a negative electrode, andan electrolyte or other material for facilitating movement of ioniccharge carriers between the negative electrode and positive electrode.As the cell is charged, cations migrate from the positive electrode tothe electrolyte and, concurrently, from the electrolyte to the negativeelectrode. During discharge, cations migrate from the negative electrodeto the electrolyte and, concurrently, from the electrolyte to thepositive electrode.

Such batteries generally include an electrochemically active materialhaving a crystal lattice structure or framework from which ions can beextracted and subsequently reinserted, and/or permit ions to be insertedor intercalated and subsequently extracted.

Recently, three-dimensionally structured compounds comprising polyanions(e.g., (SO₄)^(n−), (PO₄)^(n−), (AsO₄)^(n−), and the like), have beendevised as viable alternatives to oxide-based electrode materials suchas LiM_(x)O_(y). Examples of such polyanion-based materials include theordered olivine LiMPO₄ compounds, wherein M=Mn, Fe, Co or the like.Other examples of such polyanion-based materials include the

NASICON Li₃M₂(PO₄)₃ compounds, wherein M=Mn, Fe, Co or the like.Although these classes of lithiated polyanion-based compounds haveexhibited some promise as electrode components, many suchpolyanion-based materials are not economical to produce, affordinsufficient voltage, have insufficient charge capacity, exhibit lowionic and/or electrical conductivity, or lose their ability to berecharged over multiple cycles. Therefore, there is a current need foran electrode active material that exhibits greater charge capacity, iseconomical to produce, affords sufficient voltage, exhibits greaterionic and electrical conductivity, and retains capacity over multiplecycles.

SUMMARY OF THE INVENTION

The present invention provides novel electrode materials represented bythe general formula:

[A_(a),D_(d)]M_(m)(XY₄)_(p)Z_(e),

wherein:

(i) A is selected from the group consisting of elements from Group I ofthe Periodic Table, and mixtures thereof, and 0<a≦9;

(ii) D is at least one element with a valence state of ≧2+, and 0<d<1;

(iii) M includes at least one redox active element, and 1≦m≦3;

(iv) XY₄ is selected from the group consisting of X′[O_(4-x), Y′_(x)],X′[O_(4-y), Y′_(2y)], X″S₄, [X_(x)′″,X′_(1-z)]O₄, and mixtures thereof,wherein:

-   -   (a) X′ and X′″ are each independently selected from the group        consisting of P, As, Sb, Si, Ge, V, S, and mixtures thereof;    -   (b) X″ is selected from the group consisting of P, As, Sb, Si,        Ge, V, and mixtures thereof;    -   (c) Y′ is selected from the group consisting of a halogen, S, N,        and mixtures thereof; and    -   (d) 0≦x≦3, 0≦y≦2, 0≦z≦1, and 1≦p≦3; and

(v) Z is OH, a halogen, or mixtures thereof, and 0≦e≦4;

wherein A, D, M, X, Y, Z, a, d, x, y, z, p and e are selected so as tomaintain electroneutrality of the material.

This invention also provides electrodes which utilize an electrodeactive material of this invention. Also provided are batteries having afirst electrode that includes the electrode active material of thisinvention; a second counter-electrode having a compatible activematerial; and an electrolyte interposed there between. In a preferredembodiment, the novel electrode active material of this invention isused as a positive electrode (cathode) active material, reversiblycycling alkali metal ions with a compatible negative electrode (anode)active material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the Reitvelt refined CuKa (λ=1.5405 Å with a scatteringangle of 2θ) x-ray diffraction patterns collected for LiFePO₄,Li_(0.98)Mg_(0.01)FePO₄, and Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ activematerials.

FIG. 2 is a voltage profile of the first, third and fifth dischargecycles for a

LiCoPO₄-containing cathode (100% LiCoPO₄, 0% binder, 0% carbon) cycledwith a lithium metal anode using constant current cycling at ±0.2milliamps per square centimeter (mA/cm²) in a range of 3.0 to 5 volts(V) at a temperature of about 23° C. The electrolyte includes ethylenecarbonate (EC) and ethyl methyl carbonate (EMC) in a weight ratio of2:1, and a 1 molar concentration of LiPF₆ salt. A glass fiber separatorinterpenetrated by the solvent and the salt is interposed between thecathode and the anode.

FIG. 3 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.98)Mg_(0.05)CO_(0.96)PO₄-containing cathode (100%Li_(0.98)Mg_(0.05)CO_(0.96)PO₄, 0% binder, 0% carbon) cycled in a cellusing the test conditions described with respect to FIG. 2.

FIG. 4 is a voltage profile of the first, third and fifth dischargecycles for a LiFePO₄-containing cathode (100% LiFePO₄, 0% binder, 0%carbon) cycled in a cell using the test conditions described withrespect to FIG. 2.

FIG. 5 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.98)Mg_(0.01)FePO₄-containing cathode (100%Li_(0.98)Mg_(0.01)FePO₄, 0% binder, 0% carbon) cycled in a cell usingthe test conditions described with respect to FIG. 2.

FIG. 6 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄-containing cathode (100%Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄, 0% binder, 0% carbon) cycled in a cellusing the test conditions described with respect to FIG. 2.

FIG. 7 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.99)Nb_(0.002)FePO₄-containing cathode (100%Li_(0.99)Nb_(0.002)FePO₄, 0% binder, 0% carbon) cycled in a cell usingthe test conditions described with respect to FIG. 2.

FIG. 8 is a voltage profile of the first, third and fifth dischargecycles for a LiFePO₄/2.18% carbon-containing cathode (0% binder) cycledin a cell using the test conditions described with respect to FIG. 2.

FIG. 9 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.98)Mg_(0.01)FePO₄/1.88% carbon-containing cathode (0%binder) cycled in a cell using the test conditions described withrespect to FIG. 2.

FIG. 10 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.98)Mg_(0.04)Fe_(0.96)PO₄/2.24% carbon-containingcathode (0% binder) cycled in a cell using the test conditions describedwith respect to FIG. 2.

FIG. 11 is a voltage profile of the first, third and fifth dischargecycles for a Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄/1.98% carbon-containingcathode (0% binder) cycled in a cell using the test conditions describedwith respect to FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It has been found that the novel electrode materials, electrodes, andbatteries of this invention afford benefits over such materials anddevices among those known in the art. Such benefits include one or moreof increased capacity, enhanced cycling capability, enhancedreversibility, enhanced ionic conductivity, enhanced electricalconductivity, and reduced costs. Specific benefits and embodiments ofthe present invention are apparent from the detailed description setforth herein below. It should be understood, however, that the detaileddescription and specific examples, while indicating embodiments amongthose preferred, are intended for purposes of illustration only and arenot intended to limit the scope of the invention.

The present invention provides electrode active materials for use in anelectricity-producing electrochemical cell. Each electrochemical cellincludes a positive electrode, a negative electrode, and an electrolytein ion-transfer relationship with each electrode. As used herein, theword “include,” and its variants, is intended to be non-limiting, suchthat recitation of items in a list is not to the exclusion of other likeitems that may also be useful in the materials, compositions, devices,and methods of this invention. A “battery” refers to a device having oneor more electricity-producing electrochemical cells. Two or moreelectrochemical cells may be combined in parallel or series, or“stacked,” so as to create a multi-cell battery.

The electrode active materials of this invention may be used in thenegative electrode, the positive electrode, or both. Preferably, theactive materials of this invention are used in the positive electrode(As used herein, the terms “negative electrode” and “positive electrode”refer to the electrodes at which oxidation and reduction occur,respectively, during battery discharge; during charging of the battery,the sites of oxidation and reduction are reversed). The terms“preferred” and “preferably” as used herein refer to embodiments of theinvention that afford certain benefits, under certain circumstances.However, other embodiments may also be preferred, under the same orother circumstances. Furthermore, the recitation of one or morepreferred embodiments does not imply that other embodiments are notuseful and is not intended to exclude other embodiments from the scopeof the invention.

Electrode Active Materials of the Present Invention:

The present invention is directed to a novel alkali metal-containingelectrode active material. In one embodiment, the novel active materialof the present invention is represented by the nominal general formula(I):

[A_(a), D_(d)]M_(m)(XY₄)_(p)Z_(e.)  (I)

The term “nominal general formula” refers to the fact that the relativeproportion of atomic species may vary slightly on the order of 2 percentto 5 percent, or more typically, 1 percent to 3 percent. The compositionof A, D, M, XY₄ and Z of general formulas (I) through (V) herein, aswell as the stoichiometric values of the elements of the activematerial, are selected so as to maintain electroneutrality of theelectrode active material. The stoichiometric values of one or moreelements of the composition may take on non-integer values.

For all embodiments described herein, A is selected from the groupconsisting of elements from Group I of the Periodic Table, and mixturesthereof (e.g. A_(a)=A_(a-a′)A′_(a′), wherein A and A′ are each selectedfrom the group consisting of elements from Group I of the Periodic Tableand are different from one another, and a′<a). As referred to herein,“Group” refers to the Group numbers (i.e., columns) of the PeriodicTable as defined in the current IUPAC Periodic Table. (See, e.g., U.S.Pat. No. 6,136,472, Barker et al., issued Oct. 24, 2000, incorporated byreference herein.) In addition, the recitation of a genus of elements,materials or other components, from which an individual component ormixture of components can be selected, is intended to include allpossible sub-generic combinations of the listed components, and mixturesthereof.

In one embodiment, A is selected from the group consisting of Li(Lithium), Na (Sodium), K (Potassium), and mixtures thereof. A may bemixture of Li with Na, a mixture of Li with K, or a mixture of Li, Naand K. In another embodiment, A is Na, or a mixture of Na with K. In onepreferred embodiment, A is Li.

A sufficient quantity (a) of moiety A should be present so as to allowall of the “redox active” elements of the moiety M (as defined hereinbelow) to undergo oxidation/reduction. In one embodiment, 0<a≦9. Inanother embodiment, 0<a≦2. Unless otherwise specified, a variabledescribed herein algebraically as equal to (“=”), less than or equal to(“≦”), or greater than or equal to (“≧”) a number is intended to subsumevalues or ranges of values about equal or functionally equivalent tosaid number.

Removal of an amount of A from the electrode active material isaccompanied by a change in oxidation state of at least one of the “redoxactive” elements in the active material, as defined herein below. Theamount of redox active material available for oxidation/reduction in theactive material determines the amount (a) of the moiety A that may beremoved. Such concepts are, in general application, well known in theart, e.g., as disclosed in U.S. Pat. No. 4,477,541, Fraioli, issued Oct.16, 1984; and U.S. Pat. No. 6,136,472, Barker, et al., issued Oct. 24,2000, both of which are incorporated by reference herein.

In general, the amount (a) of moiety A in the active material variesduring charge/discharge. Where the active materials of the presentinvention are synthesized for use in preparing an alkali metal-ionbattery in a discharged state, such active materials are characterizedby a relatively high value of “a”, with a correspondingly low oxidationstate of the redox active components of the active material. As theelectrochemical cell is charged from its initial uncharged state, anamount (b) of moiety A is removed from the active material as describedabove. The resulting structure, containing less amount of the moiety A(i.e., a-b) than in the as-prepared state, and at least one of the redoxactive components having a higher oxidation state than in theas-prepared state, while essentially maintaining the original values ofthe remaining components (e.g. D, M, X, Y and Z). The active materialsof this invention include such materials in their nascent state (i.e.,as manufactured prior to inclusion in an electrode) and materials formedduring operation of the battery (i.e., by insertion or removal of A).

For all embodiments described herein, D is at least one element havingan atomic radius substantially comparable to that of the moiety beingsubstituted (e.g. moiety M and/or moiety A). In one embodiment, D is atleast one transition metal. Examples of transition metals useful hereinwith respect to moiety D include, without limitation, Nb (Niobium), Zr(Zirconium), Ti (Titanium), Ta (Tantalum), Mo (Molybdenum), W(Tungsten), and mixtures thereof. In another embodiment, moiety D is atleast one element characterized as having a valence state of ≧2+ and anatomic radius that is substantially comparable to that of the moietybeing substituted (e.g. M and/or A). With respect to moiety A, examplesof such elements include, without limitation, Nb (Niobium), Mg(Magnesium) and Zr (Zirconium). Preferably, the valence or oxidationstate of D (V^(D)) is greater than the valence or oxidation state of themoiety (or sum of oxidation states of the elements consisting of themoiety) being substituted for by moiety D (e.g. moiety M and/or moietyA).

While not wishing to be held to any one theory, with respect to moietyA, it is thought that by incorporating a dopant (D) into the crystalstructure of the active material of the present invention, wherein theamount (a) of moiety A initially present in the active material issubstituted by an amount of D, the dopant will occupy sites in theactive material normally occupied by A, thus substantially increasingthe ionic and electrical conductivity of the active material. Suchmaterials additionally exhibit enhanced electrical conductivity, thusreducing or eliminating the need for electrically conductive material(e.g. carbon) in the electrode. Reduction or elimination of carbonaceousmaterials in secondary electrochemical cells, including those disclosedherein, is desirable because of the long-term deleterious effectscarbonaceous materials produce during the operation of theelectrochemical cells (e.g. promotion of gas production within theelectrochemical cell). Reduction or elimination of the carbonaceousmaterial also permits insertion of a greater amount of active material,thereby increasing the electrochemical cell's capacity and energydensity.

Moiety A may be partially substituted by moiety D by aliovalent orisocharge substitution, in equal or unequal stoichiometric amounts.“Isocharge substitution” refers to a substitution of one element on agiven crystallographic site with an element having the same oxidationstate (e.g. substitution of Ca²⁺ with Mg²⁺). “Aliovalent substitution”refers to a substitution of one element on a given crystallographic sitewith an element of a different oxidation state (e.g. substitution of Li⁺with Mg²⁺).

For all embodiments described herein where moiety A is partiallysubstituted by moiety D by isocharge substitution, A may be substitutedby an equal stoichiometric amount of moiety D, whereby the activematerial of the present invention is represented by the nominal generalformula (II):

[A_(a-f),D_(d)]M_(m)(XY₄)_(p)Z_(e)  (II)

wherein f=d.

Where moiety A of general formula (II) is partially substituted bymoiety D by isocharge substitution and d≠f, then the stoichiometricamount of one or more of the other components (e.g. A, M, XY₄ and Z) inthe active material must be adjusted in order to maintainelectroneutrality.

For all embodiments described herein where moiety A is partiallysubstituted by moiety D by aliovalent substitution, moiety A may besubstituted by an “oxidatively” equivalent amount of moiety D, wherebythe active material of the present invention is represented by thenominal general formula (III):

$\begin{matrix}{{\lbrack {A_{a - \frac{f}{V^{A}}},D_{\frac{d}{V^{D}}}} \rbrack {M_{m}( {XY}_{4} )}_{p}Z_{e}},} & ({III})\end{matrix}$

wherein f=d, V^(A) is the oxidation state of moiety A (or sum ofoxidation states of the elements consisting of the moiety A), and V^(D)is the oxidation state of moiety D.

Where moiety A of general formula (III) is partially substituted bymoiety D by aliovalent substitution and d≠f, then the stoichiometricamount of one or more of the other components (e.g. A, M, XY₄ and Z) inthe active material must be adjusted in order to maintainelectroneutrality.

In one embodiment, moiety M is partially substituted by moiety D byaliovalent or isocharge substitution, in equal or unequal stoichiometricamounts. In this embodiment, d≧0, wherein moiety A may be substituted bymoiety D by aliovalent or isocharge substitution, in equal or unequalstoichiometric amounts. Where moieties M and A are both partiallysubstituted by moiety D, the elements selected for substitution for eachmoiety may be the same or different from one another.

For all embodiments described herein where moiety M is partiallysubstituted by moiety D by isocharge substitution, M may be substitutedby an equal stoichiometric amount of moiety D, wherebyM=[M_(m-u),D_(v)], wherein u=v. Where moiety M is partially substitutedby moiety D by isocharge substitution and u≠v, then the stoichiometricamount of one or more of the other components (e.g. A, M, XY₄ and Z) inthe active material must be adjusted in order to maintainelectroneutrality.

For all embodiments described herein where moiety M is partiallysubstituted by moiety D by aliovalent substitution, moiety M may besubstituted by an “oxidatively” equivalent amount of moiety D, whereby

$\lbrack {M_{m - \frac{u}{V^{M}}},D_{\frac{v}{V^{D}}}} \rbrack,$

wherein u=v, V^(M) is the oxidation state of moiety M (or sum ofoxidation states of the elements consisting of the moiety M), and V^(D)is the oxidation state of moiety D.

Where moiety M is partially substituted by moiety D by aliovalentsubstitution and u≠v, then the stoichiometric amount of one or more ofthe other components (e.g. A, M, XY₄ and Z) in the active material mustbe adjusted in order to maintain electroneutrality.

In this embodiment, moiety M and (optionally) moiety A are eachpartially substituted by aliovalent or isocharge substitution. While notwishing to be held to any one theory, it is thought that byincorporating a dopant (D) into the crystal structure of the activematerial of the present invention in this manner, wherein thestoichiometric values M and (optionally) A are dependent on (reduced by)the amount of dopant provided for each crystallographic site, that thedopant will occupy sites in the active material normally occupied bymoiety M and (optionally) moiety A. First, where V^(D)>V^(A), dopingsites normally occupied by A increases the number of available orunoccupied sites for A, thus substantially increasing the ionic andelectrical conductivity of the active material. Second, doping the Msites reduces the concentration of available redox active elements, thusensuring some amount of A remains in the active material upon charge,thereby increasing the structural stability of the active material. Suchmaterials additionally exhibit enhanced electrical conductivity, thusreducing or eliminating the need for electrically conductive material inthe electrode.

In all embodiments described herein, moiety M is at least one redoxactive element. As used herein, the term “redox active element” includesthose elements characterized as being capable of undergoingoxidation/reduction to another oxidation state when the electrochemicalcell is operating under normal operating conditions. As used herein, theterm “normal operating conditions” refers to the intended voltage atwhich the cell is charged, which, in turn, depends on the materials usedto construct the cell.

Redox active elements useful herein with respect to moiety M include,without limitation, elements from Groups 4 through 11 of the PeriodicTable, as well as select non-transition metals, including, withoutlimitation, Ti (Titanium), V (Vanadium), Cr (Chromium), Mn (Manganese),Fe (Iron), Co (Cobalt), Ni (Nickel), Cu (Copper), Nb (Niobium), Mo(Molybdenum), Ru (Ruthenium), Rh (Rhodium), Pd (Palladium), Os (Osmium),Ir (Iridium), Pt (Platinum), Au (Gold), Si (Silicon), Sn (Tin), Pb(Lead), and mixtures thereof. Also, “include,” and its variants, isintended to be non-limiting, such that recitation of items in a list isnot to the exclusion of other like items that may also be useful in thematerials, compositions, devices, and methods of this invention.

In one embodiment, moiety M is a redox active element. In onesubembodiment, M is a redox active element selected from the groupconsisting of Ti²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺, Cu²⁺, Mo²⁺, Si²⁺,Sn²⁺, and Pb²⁺. In another subembodiment, M is a redox active elementselected from the group consisting of Ti³⁺, V³⁺, Cr³⁺, Mn³⁺, Fe³⁺, Co³⁺,Ni³⁺, Mo³⁺, and Nb³⁺.

In another embodiment, moiety M is a mixture of redox active elements ora mixture of at least one redox active element and at least onenon-redox active element. As referred to herein, “non-redox activeelements” include elements that are capable of forming stable activematerials, and do not undergo oxidation/reduction when the electrodeactive material is operating under normal operating conditions.

Among the non-redox active elements useful herein include, withoutlimitation, those selected from Group 2 elements, particularly Be(Beryllium), Mg (Magnesium), Ca (Calcium), Sr (Strontium), Ba (Barium);Group 3 elements, particularly Sc (Scandium), Y (Yttrium), and thelanthanides, particularly La (Lanthanum), Ce (Cerium), Pr(Praseodymium), Nd (Neodymium), Sm (Samarium); Group 12 elements,particularly Zn (Zinc) and Cd (Cadmium); Group 13 elements, particularlyB (Boron), Al (Aluminum), Ga (Gallium), In (Indium), TI (Thallium);Group 14 elements, particularly C (Carbon) and Ge (Germanium), Group 15elements, particularly As (Arsenic), Sb (Antimony), and Bi (Bismuth);Group 16 elements, particularly Te (Tellurium); and mixtures thereof.

In one embodiment, M=MI_(n)MII_(o), wherein 0<o+n≦3 and each of o and nis greater than zero (0<o,n), wherein MI and MII are each independentlyselected from the group consisting of redox active elements andnon-redox active elements, wherein at least one of MI and MII is redoxactive. MI may be partially substituted with MII by isocharge oraliovalent substitution, in equal or unequal stoichiometric amounts.

For all embodiments described herein where MI is partially substitutedby MII by isocharge substitution, MI may be substituted by an equalstoichiometric amount of MII, whereby M=MI_(n-o)MII_(o). Where MI ispartially substituted by MII by isocharge substitution and thestoichiometric amount of MI is not equal to the amount of MII, wherebyM=MI_(n-o)MII_(p) and o≠p, then the stoichiometric amount of one or moreof the other components (e.g. A, D, XY₄ and Z) in the active materialmust be adjusted in order to maintain electroneutrality.

For all embodiments described herein where MI is partially substitutedby MII by aliovalent substitution and an equal amount of MI issubstituted by an equal amount of MII, whereby M=MI_(n-o)MII_(o), thenthe stoichiometric amount of one or more of the other components (e.g.A, D, XY₄ and Z) in the active material must be adjusted in order tomaintain electroneutrality. However, MI may be partially substituted byMII by aliovalent substitution by substituting an “oxidatively”equivalent amount of MII for MI, whereby

${M = {{MI}_{n - \frac{o}{V^{MI}}}{MII}_{\frac{o}{V^{MII}}}}},$

wherein V^(MI) is the oxidation state of MI, and V^(III) is theoxidation state of MII.

In one subembodiment, MI is selected from the group consisting of Ti, V,Cr, Mn, Fe, Co, Ni, Cu, Mo, Si, Pb, Mo, Nb, and mixtures thereof, andMII is selected from the group consisting of Be, Mg, Ca, Sr, Ba, Sc, Y,Zn, Cd, B, Al, Ga, In, C, Ge, and mixtures thereof. In thissubembodiment, MI may be substituted by MII by isocharge substitution oraliovalent substitution.

In another subembodiment, MI is partially substituted by MII byisocharge substitution. In one aspect of this subembodiment, MI isselected from the group consisting of Ti²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺,Ni²⁺, Cu²⁺, Mo²⁺, Si²⁺, Sn²⁺, Pb²⁺, and mixtures thereof, and MII isselected from the group consisting of Be²⁺, Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺,Zn²⁺, Cd²⁺, Ge²⁺, and mixtures thereof. In another aspect of thissubembodiment, MI is selected from the group specified immediatelyabove, and MII is selected from the group consisting of Be²⁺, Mg²⁺,Ca²⁺, Sr²⁺, Ba²⁺, and mixtures thereof. In another aspect of thissubembodiment, MI is selected from the group specified above, and MII isselected from the group consisting of Zn²⁺, Cd²⁺, and mixtures thereof.In yet another aspect of this subembodiment, MI is selected from thegroup consisting of Ti³⁺, V³⁺, Cr³⁺, Mn³⁺, Fe³⁺, Co³⁺, Ni³⁺, Mo³⁺, Nb³⁺,and mixtures thereof, and MII is selected from the group consisting ofSc³⁺, Y³⁺, B³⁺, Al³⁺, Ga³⁺, In³⁺, and mixtures thereof.

In another embodiment, MI is partially substituted by MII by aliovalentsubstitution. In one aspect of this subembodiment, MI is selected fromthe group consisting of Ti²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺, Cu²⁺,Mo²⁺, Si²⁺, Sn²⁺, Pb²⁺, and mixtures thereof, and MII is selected fromthe group consisting of Sc³⁺, Y³⁺, B³⁺, Al³⁺, Ga³⁺, In³⁺, and mixturesthereof. In another aspect of this subembodiment, MI is a 2+ oxidationstate redox active element selected from the group specified immediatelyabove, and MII is selected from the group consisting of alkali metals,Cu¹⁺, Ag¹⁺ and mixtures thereof. In another aspect of thissubembodiment, MI is selected from the group consisting of Ti³⁺, V³⁺,Cr³⁺, Mn³⁺, Fe³⁺, Co³⁺, Ni³⁺, Mo³⁺, Nb³⁺, and mixtures thereof, and MIIis selected from the group consisting of Be²⁺, Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺,Zn Cd Cd²⁺, Ge²⁺, and mixtures thereof. In another aspect of thissubembodiment, MI is a 3+ oxidation state redox active element selectedfrom the group specified immediately above, and MII is selected from thegroup consisting of alkali metals, Cu¹⁺, Ag¹⁺ and mixtures thereof.

In another embodiment, M=M1_(q)M2_(r)M3_(s), wherein:

(a) M1 is a redox active element with a 2+ oxidation state;

(b) M2 is selected from the group consisting of redox and non-redoxactive elements with a 1+ oxidation state;

(c) M3 is selected from the group consisting of redox and non-redoxactive elements with a 3+ oxidation state; and

(d) at least one of p, q and r is greater than 0, and at least one ofM1, M2, and M3 is redox active.

In one subembodiment, M1 is substituted by an equal amount of M2 and/orM3, whereby q=q−(r+s). In this subembodiment, then the stoichiometricamount of one or more of the other components (e.g. A, XY₄, Z) in theactive material must be adjusted in order to maintain electroneutrality.

In another subembodiment, M¹ is substituted by an “oxidatively”equivalent amount of M² and/or M³, whereby

${M = {M\; 1_{q - \frac{r}{V^{M\; 1}} - \frac{s}{V^{M\; 1}}}M\; 2_{\frac{r}{V^{M\; 2}}}M\; 3_{\frac{s}{V^{M\; 3}}}}},$

wherein V^(M1) is the oxidation state of M1, V^(M2) is the oxidationstate of M2, and V^(M3) is the oxidation state of M3.

In one subembodiment, M1 is selected from the group consisting of Ti²⁺,V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺, Cu²⁺, Mo²⁺, Si²⁺, Sn²⁺, Pb²⁺, andmixtures thereof; M2 is selected from the group consisting of Cu¹⁺, Ag¹⁺and mixtures thereof; and M3 is selected from the group consisting ofTi³⁺, V³⁺, Cr³⁺, Mn³⁺, Fe³⁺, Co³⁺, Ni³⁺, Mo³⁺, Nb³⁺, and mixturesthereof. In another subembodiment, M1 and M3 are selected from theirrespective preceding groups, and M2 is selected from the groupconsisting of Li¹⁺, K¹⁺, Na^(l+), Ru¹⁺, Cs¹⁺, and mixtures thereof.

In another subembodiment, M1 is selected from the group consisting ofBe²⁺, Mg ²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Zn²⁺, Cd²⁺, Ge ²⁺, and mixtures thereof;Cu¹⁺, Ag and mixtures thereof; and M3 is selected from the groupconsisting of Ti³⁺, V³⁺, Cr³⁺, Mn³⁺, Fe³⁺, Co³⁺, Ni³⁺, Mo³⁺, Nb³⁺, andmixtures thereof. In another subembodiment, M1 and M3 are selected fromtheir respective preceding groups, and M2 is selected from the groupconsisting of Li¹⁺, K¹⁺, Na¹⁺, Ru¹⁺, Cs¹⁺, and mixtures thereof.

In another subembodiment, M1 is selected from the group consisting ofTi²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺, Cu²⁺, Mo²⁺, Si²⁺, Sn²⁺, Pb²⁺,and mixtures thereof; M2 is selected from the group consisting of Cu¹⁺,Ag¹⁺, and mixtures thereof; and M3 is selected from the group consistingof Sc³⁺, Y³⁺, B³⁺, Al³⁺, Ga³⁺, In³⁺, and mixtures thereof.

In another subembodiment, M1 and M3 are selected from their respectivepreceding groups, and M2 is selected from the group consisting of Li¹⁺,K¹⁺, Na¹⁺, Ru¹⁺, Cs¹⁺, and mixtures thereof.

In all embodiments described herein, moiety XY₄ is a polyanion selectedfrom the group consisting of X′[O_(4-x),Y′_(x)], X′[O_(4-y),Y′_(2y)],X″S₄, [X_(z′″),X′_(1-z)]O₄, and mixtures thereof, wherein:

(a) X′ and X′″ are each independently selected from the group consistingof P, As, Sb, Si, Ge, V, S, and mixtures thereof;

(b) X″ is selected from the group consisting of P, As, Sb, Si, Ge, V,and mixtures thereof; (c) Y′ is selected from the group consisting of ahalogen, S, N, and mixtures thereof; and

(d) 0≦x≦3, 0≦y≦2, and 0≦z≦1.

In one embodiment, 1≦p≦3. In one subembodiment, p=1. In anothersubembodiment, p=3.

In one embodiment, XY₄ is selected from the group consisting ofX′O_(4-x)Y′_(x), X′O_(4-y)Y′_(2y), and mixtures thereof, and x and y areboth 0. Stated otherwise, XY₄ is a polyanion selected from the groupconsisting of PO₄, SiO₄, GeO₄, VO₄, AsO₄, SbO₄, SO₄, and mixturesthereof. Preferably, XY₄ is PO₄ (a phosphate group) or a mixture of PO₄with another anion of the above-noted group (i.e., where X′ is not P, Y′is not O, or both, as defined above). In one embodiment, XY₄ includesabout 80% or more phosphate and up to about 20% of one or more of theabove-noted anions.

In another embodiment, XY₄ is selected from the group consisting ofX′[O_(4-x),Y′_(x)], X′[O_(4-y),Y′_(2y)], and mixtures thereof, and 0<x≦3and 0<y≦2, wherein a portion of the oxygen (O) in the XY₄ moiety issubstituted with a halogen, S, N, or a mixture thereof.

In all embodiments described herein, moiety Z (when provided) isselected from the group consisting of OH (Hydroxyl), a halogen, ormixtures thereof. In one embodiment, Z is selected from the groupconsisting of OH, F (Fluorine), Cl (Chlorine), Br (Bromine), andmixtures thereof. In another embodiment, Z is OH. In another embodiment,Z is F, or a mixture of F with OH, Cl, or Br. Where the moiety Z isincorporated into the active material of the present invention, theactive material may not take on a NASICON or olivine structural wherep=3 or d=1, respectively. It is quite normal for the symmetry to bereduced with incorporation of, for example, halogens

The composition of the electrode active material, as well as thestoichiometric values of the elements of the composition, are selectedso as to maintain electroneutrality of the electrode active material.The stoichiometric values of one or more elements of the composition maytake on non-integer values. Preferably, the XY₄ moiety is, as a unitmoiety, an anion having a charge of −2, −3, or −4, depending on theselection of X′, X″, X′″ Y′, and x and y. When XY₄ is a mixture ofpolyanions such as the preferred phosphate/phosphate substitutesdiscussed above, the net charge on the XY₄ anion may take on non-integervalues, depending on the charge and composition of the individual groupsXY₄ in the mixture.

In one particular embodiment, the electrode active material has anorthorhombic-dipyramidal crystal structure and belongs to the spacegroup Pbnm (e.g. an olivine or triphylite material), and is representedby the nominal general formula (II):

[A_(a),D_(d)]M_(m)XY₄Z_(e)  (IV)

wherein:

(a) the moieties A, D, M, X, Y and Z are as defined herein above;

(b) 0<a≦2, 0<d≦1; 1<m≦2, and 0<d≦1; and

(c) the components of the moieties A, D, M, X, Y, and Z, as well as thevalues for a, d, m and e, are selected so as to maintainelectroneutrality of the compound.

In one particular subembodiment, A of general formula (IV) is Li,0.5<a≦1.5, M=MI_(n-p)MII_(o), wherein o=p, 0.5<n≦1.5, 0<o≦0.1, MI is a2+ oxidation state redox active element selected from the groupconsisting of Ti²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺, Cu²⁺, Mo²⁺, Si²⁺,Sn²⁺, and Pb²⁺ (preferably Fe²⁺), MII is selected from the groupconsisting of Be²⁺, Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Zn²⁺, Cd²⁺, Ge²⁺, andmixtures thereof (preferably Mg²⁺ or Ca²⁺), XY₄=PO₄, and e=0.

In another particular embodiment, the electrode active material has arhombohedral (space group R-3) or monoclinic (space group Pbcn) NASICONstructure, and is represented by the nominal general formula (V):

[A_(a), D_(d)]M_(m)(XY₄)₃Z_(e)  (V)

wherein:

(a) the moieties A, D, M, X, Y and Z are as defined herein above;

(b) 0<a≦5, 0<d≦1; 1<m≦3, and 0<e≦4; and

(c) the components of the moieties A, D, M, X, Y, and Z, as well as thevalues for a, d, m and e, are selected so as to maintainelectroneutrality of the compound. In one particular subembodiment, A ofgeneral formula (V) is Li, M is selected from the group consisting ofTi³⁺, V³⁺, Cr³⁺, Mn³⁺, Fe³⁺, Co³⁺, Ni³⁺, Mo³⁺, Nb³⁺, and mixturesthereof (preferably V³⁺), XY₄=PO₄, and e=0.

Methods of Manufacture:

The particular starting materials employed will depend on the particularactive material to be synthesized, reaction method employed, and desiredby-products. The compound of the present invention is synthesized byreacting at least one A-containing compound, at least one D-containingcompound, one or more M-containing compounds, at least one XY₄-supplyingor containing compound, and (optionally) one or more Z-containingcompounds, at a temperature and for a time sufficient to form thedesired reaction product. As used herein, the term “supplying” includescompounds which contain the particular component, or reacts to form theparticular component so specified.

Sources of the moiety A include any of a number of Group Imetal-containing salts or ionic compounds. Lithium, sodium, andpotassium compounds are preferred, with lithium being particularlypreferred. Examples include, without limitation, alkali metal-containingfluorides, chlorides, bromides, iodides, nitrates, nitrites, sulfates,hydrogen sulfates, sulfites, bisulfites, carbonates, bicarbonates,borates, phosphates, silicates, antimonates, arsenates, germinates,oxides, acetates, oxalates, and the like. Hydrates of the abovecompounds may also be used, as well as mixtures thereof. The mixturesmay contain more than one alkali metal so that a mixed alkali metalactive material will be produced in the reaction.

Sources of the moieties M and D include, without limitation,M/D-containing fluorides, chlorides, bromides, iodides, nitrates,nitrites, sulfates, hydrogen sulfates, sulfites, bisulfites, carbonates,bicarbonates, borates, phosphates, hydrogen ammonium phosphates,dihydrogen ammonium phosphates, silicates, antimonates, arsenates,germanates, oxides, hydroxides, acetates, and oxalates of the same.Hydrates may also be used. The moiety M in the starting material mayhave any oxidation state, depending on the oxidation state required inthe desired product and the oxidizing or reducing conditionscontemplated, if any. It should be noted that many of the above-notedcompounds may also function as a source of the XY₄ moiety.

The active materials described herein can contain one or more XY₄moieties, or can contain a phosphate group that is completely orpartially substituted by a number of other XY₄ moieties, which will alsobe referred to as “phosphate replacements” or “modified phosphates.”Thus, active materials are provided according to the invention whereinthe XY₄ moiety is a phosphate group that is completely or partiallyreplaced by such moieties as sulfate (SO₄)²⁻, monofluoromonophosphate,(PO₃F)²⁻, difluoromonophosphate (PO₂F)²⁻, silicate (SiO₄)⁴⁻, arsenate,antimonate, vanadate, titanate, and germanate. Analogues of the aboveoxygenate anions where some or all of the oxygen is replaced by sulfurare also useful in the active materials of the invention, with theexception that the sulfate group may not be completely substituted withsulfur. For example, thiomonophosphates may also be used as a completeor partial replacement for phosphate in the active materials of theinvention. Such thiomonophosphates include the anions (PO₃S)³⁻,(PO₂S₂)³⁻, (POS₃)³⁻, and (PS₄)³⁻, and are most conveniently available asthe sodium, lithium, or potassium derivative. Non-limiting examples ofsources of monofluoromonophosphates include, without limitation,Na₂PO₃F, K₂PO₃F, (NH₄)₂PO₃F.H₂O, LiNaPO₃F.H₂O, LiKPO₃F, LiNH₄PO₃F,NaNH₄PO₃F, NaK₃(PO₃F)₂ and CaPO₃.2H₂O. Representative examples ofsources of difluoromonophosphate compounds include, without limitation,NH₄PO₂F₂, NaPO₂F₂, KPO₂F₂, Al(PO₂F₂)₃, and Fe(PO₂F₂)₃.

Sources for the XY₄ moiety are common and readily available. Forexample, where X is Si, useful sources of silicon includeorthosilicates, pyrosilicates, cyclic silicate anions such as (Si₃O₉)⁶⁻,(Si₆O₁₈)¹²⁻ and the like, and pyrocenes represented by the formula[(SiO₃)²⁻]_(n), for example LiAl(SiO₃)₂. Silica or SiO₂ may also beused. Representative arsenate compounds that may be used to prepare theactive materials of the invention, wherein X is As, include H₃AsO₄ andsalts of the anions [H₂AsO₄]⁻ and [HAsO₄]²⁻. Where X is Sb, antimonatecan be provided by antimony-containing materials such as Sb₂O₅, M¹SbO₃where M¹ is a metal having oxidation state 1+, M^(III)SbO₄ where M^(III)is a metal having an oxidation state of 3+, and M^(II)Sb₂O₇ where M^(II)is a metal having an oxidation state of 2+. Additional sources ofantimonate include compounds such as Li₃SbO₄, NH₄H₂SbO₄, and otheralkali metal and/or ammonium mixed salts of the [SbO₄]³⁻ anion. Where Xis S, sulfate compounds that can be used to synthesize the activematerial include alkali metal and transition metal sulfates andbisulfates as well as mixed metal sulfates such as (NH₄)₂Fe(SO₄)₂,NH₄Fe(SO₄)₂ and the like. Finally, where X is Ge, a germanium containingcompound such as GeO₂ may be used to synthesize the active material.

Where Y′ of the X′O_(4-x)Y′_(x) and X′O_(4-y)Y′_(2y) moieties is F,sources of F include ionic compounds containing fluoride ion (F⁻) orhydrogen difluoride ion (HF₂ ⁻). The cation may be any cation that formsa stable compound with the fluoride or hydrogen difluoride anion.Examples include 1+, 2+ and 3+ metal cations, as well as ammonium andother nitrogen-containing cations. Ammonium is a preferred cationbecause it tends to form volatile by-products that are readily removedfrom the reaction mixture. Similarly, to make X′O_(4-x)N_(x), startingmaterials are provided that contain “x” moles of a source of nitrideion. Sources of nitride are among those known in the art includingnitride salts such as Li₃N and (NH₄)₃N.

As noted above, the active materials of the present invention contain amixture of A, D, M, XY₄, and (optionally) Z. A starting material mayprovide more than one these components, as is evident in the list above.In various embodiments of the invention, starting materials are providedthat combine, for example, M and PO₄, thus requiring only the alkalimetal and D to be added. In one embodiment, a starting material isprovided that contains A, M and PO₄. As a general rule, there issufficient flexibility to allow selection of starting materialscontaining any of the components of alkali metal A, D, M, XY₄, and(optionally) Z, depending on availability. Combinations of startingmaterials providing each of the components may also be used.

In general, any counterion may be combined with A, D, M, XY₄, and Z. Itis preferred, however, to select starting materials with counterionsthat give rise to the formation of volatile by-products during thereaction. Thus, it is desirable to choose ammonium salts, carbonates,bicarbonates, oxides, hydroxides, and the like, where possible. Startingmaterials with these counterions tend to form volatile by-products suchas water, ammonia, and carbon dioxide, which can be readily removed fromthe reaction mixture. Similarly, sulfur-containing anions such assulfate, bisulfate, sulfite, bisulfite and the like tend to result involatile sulfur oxide by-products. Nitrogen-containing anions such asnitrate and nitrite also tend to give volatile NO_(x) by-products. Thisconcept is well illustrated in the examples below.

Additionally, in some cases the performance of the active material maybe dependent upon the amount of each reactant present in the reactionmixture. This is because the presence of certain unreacted startingmaterials in the active material may have a detrimental effect on theelectrochemical performance of the active material. For example, withrespect to the active material Li_(a)Mg_(b)Fe_(c)PO₄, synthesized via asolid state reaction of LiH₂PO₄ and Fe₂O₃ in the presence of a reducingagent (as defined herein below), it has been discovered that thepresence of Fe₂O₃ in the reaction product has a deleterious effect onthe electrochemical performance of the active material. Therefore, inthis particular reaction, it is preferred that the Fe₂O₃ be the limitingreagent to ensure that substantially all of the Fe₂O₃ reacts.Preferably, for this particular reaction, it is preferred that the P toM ration (P:M) be approximately 1:0.95 to about 1:0.99. Furthermore,depending on the particular source of LiH₂PO₄, the Li:P ratio of LiH₂PO₄may not be exactly 1:1 due to the presence of unreacted reactants usedto synthesize LiH₂PO₄ (e.g. H₃PO₄). For example, if a LiH₂PO₄ materialof 98% purity (e.g. containing 2% H₃PO₄) is employed, the Li:P ration inthe reaction mixture is 0.98:1. Preferably, the overall Li:P:M ratio isfrom about 0.95:1:95 to about 0.99:1:0.99, and most preferably0.98:1:0.96. Thus, as can be seen from the above-noted example, one withordinary skill in the art would readily be able to optimize theelectrochemical performance of the active material synthesized bychoosing one of the reactant to be the limiting reagent, taking intoaccount any impurities present in the reaction mixture, and comparingthe electrochemical performance of the resulting active material tosimilar active materials wherein alternate reactants are chosen to bethe limiting reagent.

One method for preparing the active materials of the present inventionis via the hydrothermal treatment of the requisite starting materials.In a hydrothermal reaction, the starting materials are mixed with asmall amount of a liquid (e.g. water), and heated in a pressurizedvessel or bomb at a temperature that is relatively lower as compared tothe temperature necessary to produce the active material in an oven atambient pressure.

Preferably, the reaction is carried out at a temperature of about 150°C. to about 450° C., under pressure, for a period of about 4 to about 48hours, or until a reaction product forms.

A “sol-gel” preparation method may also be employed. Using this method,solute precursors with the required component are mixed in solution andthen transformed into a solid via precipitation or gelation. The resultwet powder or gel are dried at temperature in the range of about 100° C.to about 400° C. for short time and then, optionally, heated up to about450° C. to about 700° C. in controlled atmosphere for about 1 hour toabout 4 hours.

Another method for synthesizing the active materials of the presentinvention is via a thermite reaction, wherein M is reduced by a granularor powdered metal present in the reaction mixture.

The active materials of the present invention can also be synthesizedvia a solid state reaction, with or without simultaneous oxidation orreduction of those elements in the compound that are redox active, byheating the requisite starting materials at an elevated temperature fora given period of time, until the desired reaction product forms. In asolid-state reaction, the starting materials are provided in powder orparticulate form, and are mixed together by any of a variety ofprocedures, such as by ball milling, blending in a mortar and pestle,and the like. Thereafter, the mixture of powdered starting materials maybe compressed into a pellet and/or held together with a binder (whichmay also serve as a source of reducing agent) material to form a closelycohering reaction mixture. The reaction mixture is heated in an oven,generally at a temperature of about 400° C. or greater, until a reactionproduct forms.

The reaction may be carried out under reducing or oxidizing conditions,to reduce the oxidation state of M or to maintain the oxidation state ofthe M moiety. Reducing conditions may be provided by performing thereaction in a “reducing atmosphere” such as hydrogen, ammonia, carbonmonoxide, methane, mixtures of thereof, or other suitable reducing gas.Reduction conditions may also be provided by conducting the reactionunder low oxygen partial pressures. Alternatively or in additionthereto, the reduction may be carried out in situ by including in thereaction mixture a reductant that will participate in the reaction toreduce M, but that will produce by-products that will not interfere withthe active material when used later in an electrode or anelectrochemical cell.

In one embodiment, the reductant is elemental carbon, wherein thereducing power is provided by simultaneous oxidation of carbon to carbonmonoxide and/or carbon dioxide. An excess of carbon, remaining after thereaction, is intimately mixed with the product active material andfunctions as a conductive constituent in the ultimate electrodeformulation. Accordingly, excess carbon, on the order of 100% orgreater, may be used. The presence of carbon particles in the startingmaterials also provides nucleation sites for the production of theproduct crystals.

The source of reducing carbon may also be provided by an organicmaterial that forms a carbon-rich decomposition product, referred toherein as a “carbonaceous material,” and other by-products upon heatingunder the conditions of the reaction. At least a portion of the organicprecursor, carbonaceous material and/or by-products formed functions asa reductant during the synthesis reaction for the active material,before, during and/or after the organic precursor undergoes thermaldecomposition. Such precursors include any liquid or solid organicmaterial (e.g. sugars and other carbohydrates, including derivatives andpolymers thereof, acetates and acrylates).

Although the reaction may be carried out in the presence of oxygen, thereaction is preferably conducted under an essentially non-oxidizingatmosphere so as not to interfere with the reduction reactions takingplace. An essentially non-oxidizing atmosphere can be achieved throughthe use of vacuum, or through the use of inert gases such as argon andthe like.

Preferably, the particulate starting materials are heated to atemperature below the melting point of the starting materials. Thetemperature should be about 400° C. or greater, and desirably about 450°C. or greater. CO and/or CO₂ evolve during the reaction. Highertemperatures favor CO formation. Some of the reactions are moredesirably conducted at temperatures greater than about 600° C.; mostdesirably greater than about 650° C. Suitable ranges for many reactionsare from about 500° C. to about 1200° C.

At about 700° C. both the C→CO and the C→CO₂ reactions are occurring. Atcloser to about 600° C. the C→CO₂ reaction is the dominant reaction. Atcloser to about 800° C. the C→CO reaction is dominant. Since thereducing effect of the C→CO₂ reaction is greater, the result is thatless carbon is needed per atomic unit of metal to be reduced. COproduced during the C→CO reaction may be further involved in thereduction reaction via the CO→CO₂ reaction.

The starting materials may be heated at ramp rates from a fraction of adegree up to about 10° C. per minute. Once the desired reactiontemperature is attained, the reactants (starting materials) are held atthe reaction temperature for a time sufficient for the reaction tooccur. Typically, the reaction is carried out for several hours at thefinal reaction temperature.

After reaction, the products are preferably cooled from the elevatedtemperature to ambient (room) temperature (i.e., about 10° C. to about40° C.). It is also possible to quench the products to achieve a highercooling rate, for example on the order of about 100° C./minute. Thethermodynamic considerations such as ease of reduction of the selectedstarting materials, the reaction kinetics, and the melting point of thesalts will cause adjustment in the general procedure, such as the amountof reducing agent, the temperature of the reaction, and the dwell time.

Electrochemical Cells:

To form an electrode, the active material of the present invention maybe combined with a polymeric binder in order to form a cohesive mixture.The mixture this then placed in electrical communication with a currentcollector which, in turn, provides electrical communication between theelectrode and an external load. The mixture may be formed or laminatedonto the current collector, or an electrode film may be formed from themixture wherein the current collector is embedded in the film. Suitablecurrent collectors include reticulated or foiled metals (e.g. aluminum,copper and the like). An electrically conductive agent (e.g. carbon andthe like) may be added to the mixture so as to increase the electricalconductivity of the electrode. In one embodiment, the electrode materialis pressed onto or about the current collector, thus eliminating theneed for the polymeric binder.

To form an electrochemical cell, a solid electrolyte or anelectrolyte-permeable separator is interposed between the electrode anda counter-electrode. In one embodiment, the counter-electrode containsan intercalation active material selected from the group consisting of atransition metal oxide, a metal chalcogenide, carbon (e.g. graphite),and mixtures thereof. Counter electrodes, electrolyte compositions, andmethods for making the same, among those useful herein, are described inU.S. Ser. No. 10/323,457, filed Dec. 18, 2002; U.S. Pat. No. 5,700,298,Shi et al., issued Dec. 23, 1997; U.S. Pat. No. 5,830,602, Barker etal., issued Nov. 3, 1998; U.S. Pat. No. 5,418,091, Gozdz et al., issuedMay 23, 1995; U.S. Pat. No. 5,508,130, Golovin, issued Apr. 16, 1996;U.S. Pat. No. 5,541,020, Golovin et al., issued Jul. 30, 1996; U.S. Pat.No. 5,620,810, Golovin et al., issued Apr. 15, 1997; U.S. Pat. No.5,643,695, Barker et al., issued Jul. 1, 1997; U.S. Pa. No. 5,712,059,Barker et al., issued Jan. 27, 1997; U.S. Pat. No. 5,851,504, Barker etal., issued Dec. 22, 1998; U.S. Pat. No. 6,020,087, Gao, issued Feb. 1,2001; and U.S. Pat. No. 6,103,419, Saidi et al., issued Aug. 15, 2000;all of which are incorporated by reference herein.

Electrochemical cells composed of electrodes, electrolytes and othermaterials, among those useful herein, are described in the followingdocuments, all of which are incorporated by reference herein: U.S. Pat.No. 4,668,595, Yoshino et al., issued May 26, 1987; U.S. Pat. No.4,792,504, Schwab et al., issued Dec. 20, 1988; U.S. Pat. No. 4,830,939,Lee et al., issued May 16, 1989; U.S. Pat. No. 4,935,317, Fauteaux etal., issued Jun. 19, 1980; U.S. Pat. No. 4,990,413, Lee et al., issuedFeb. 5, 1991; U.S. Pat. No. 5,037,712, Shackle et al., issued Aug. 6,1991; U.S. Pat. No. 5,262,253, Golovin, issued Nov. 16, 1993; U.S. Pat.No. 5,300,373, Shackle, issued Apr. 5, 1994; U.S. Pat. No. 5,399,447,Chaloner-Gill, et al., issued Mar. 21, 1995; U.S. Pat. No. 5,411,820,Chaloner-Gill, issued May 2, 1995; U.S. Pat. No. 5,435,054, Tonder etal., issued Jul. 25, 1995; U.S. Pat. No. 5,463,179, Chaloner-Gill etal., issued Oct. 31, 1995; U.S. Pat. No. 5,482,795, Chaloner-Gill.,issued Jan. 9, 1996; U.S. Pat. No. 5,660,948, Barker, issued Sep. 16,1995; and U.S. Pat. No. 6,306,215, Larkin, issued Oct. 23, 2001.

Synthesis and Characterization of Active Materials:

The following non-limiting examples illustrate the compositions andmethods of the present invention.

EXAMPLE 1

Reaction A—Synthesis of Li_(a)Nb_(b)MnPO₄.

LiH₂PO₄+Mn(CH₃CO₂)₂·4H₂O+Nb₂O₅+NH₄H₂PO₄→Li_(a)Nb_(b)MnPO₄  (A)

Li_(a)Nb_(b)MnPO₄ active material synthesized per reaction A isaccomplished by first combining the reactants, and then ball milling thesame to mix the particles. Thereafter, the particle mixture ispelletized. The pelletized mixture is heated for about 4 hours at about700° C. in an oven in a flowing inert atmosphere (e.g. argon).Thereafter, the sample is cooled and then removed from the oven. Tosynthesize active material with no residual carbon (which is present dueto the pyrolization of any organic material present in the reactionmixture), a high flow-rate inert atmosphere or partially oxidizingatmosphere is employed.

Several compounds having the general formula Li_(a)Nb_(b)MnPO₄ weresynthesized per reaction A. Because these compounds exhibited lowelectrical conductivity, electrochemical performance data could not beobtained experimentally. Table 1 below summarizes the reactants employedand their respective amounts for each compound synthesized. In eachexample herein below, the weight in grams of each reactant was adjustedto account for impurities present in the particular reactant.

TABLE 1 Sample LiH₂PO₄ Mn(CH₃CO₂)₂•4H₂O Nb₂O₅ NH₄H₂PO₄ No. 103.93 g/mol245.09 g/mol 265.81 g/mol 115.03 g/mol Li_(a)Nb_(b)MnPO₄ 1 0.99 mol 1mol 0.001 mol 0.01 mol a = 0.99 b = 0.002 2 0.98 mol 1 mol 0.002 mol0.02 mol a = 0.98 b = 0.004 3 0.97 mol 1 mol 0.003 mol 0.03 mol a = 0.97b = 0.006 4 0.96 mol 1 mol 0.004 mol 0.04 mol a = 0.96 b = 0.008

EXAMPLE 2

Reaction B—Synthesis of Li_(a)Mg_(b)Mn_(c)PO₄.

LiH₂PO₄+Mn(CH₃CO₂)₂·4H₂O+Mg(CH₃CO₂)₂·4H₂O+NH₄H₂PO₄→Li_(a)Mg_(b)Mn_(c)PO₄  (B)

Several compounds having the general formula Li_(a)Mg_(b)Mn_(c)PO₄ weresynthesized per reaction B, per the reaction conditions of Example 1.Because these compounds exhibited low electrical conductivity,electrochemical performance data could not be obtained experimentally.Table 2 below summarizes the reactants employed and their respectiveamounts for each compound synthesized.

TABLE 2 Sample LiH₂PO₄ Mn(CH₃CO₂)₂•4H₂O Mg(CH₃CO₂)₂•4H₂O NH₄H₂PO₄ No.103.93 g/mol 245.09 g/mol 214.46 g/mol 115.03 g/molLi_(a)Mg_(b)Mn_(c)PO4 1 0.98 mol 1 mol 0.01 mol 0.02 mol a = 0.98 b =0.01, c = 1 2 0.96 mol 1 mol 0.02 mol 0.04 mol a = 0.96 b = 0.02, c = 13 0.94 mol 1 mol 0.03 mol 0.06 mol a = 0.94 b = 0.03, c = 1 4 0.96 mol 1mol 0.05 mol 0.02 mol a = 0.98, b = 0.05, c = 0.96

EXAMPLE 3

Reaction C—Synthesis of Li_(a)Zr_(b)MnPO₄.

LiH₂PO₄+Zr(OC₂H₅)₄+Mn(CH₃CO₂)₂·4H₂O +NH₄H₂PO₄→Li_(a)Zr_(b)MnPO₄  (C)

Several compounds having the general formula Li_(a)Zr_(b)MnPO₄ weresynthesized per reaction C, per the reaction conditions of Example 1.Because these compounds exhibited low electrical conductivity,electrochemical performance data could not be obtained experimentally.Table 3 below summarizes the reactants employed and their respectiveamounts for each compound synthesized.

TABLE 3 Sample LiH₂PO₄ Zr(OC₂H₅)₄ Mn(CH₃CO₂)₂•4H₂O NH₄H₂PO₄ No. 103.93g/mol 271.41 g/mol 245.09 g/mol 115.03 g/mol Li_(a)Zr_(b)MnPO₄ 1 0.98mol 0.005 mol 1 mol 0.02 mol a = 0.98 b = 0.005 2 0.96 mol  0.01 mol 1mol 0.04 mol a = 0.96 b = 0.01

EXAMPLE 4

Reaction D—Synthesis of Li_(a)Zr_(b)V₂(PO₄)₃.

LiH₂PO₄+Zr(OC₂H₅)₄+V₂O₃+NH₄H₂PO₄→Li_(a)Zr_(b)V₂(PO₄)₃  (D)

Several compounds having the general formula Li_(a)Zr_(b)V₂(PO₄)₃ weresynthesized per reaction D, per the reaction conditions of Example 1.Table 4 below summarizes the reactants employed and their respectiveamounts for each compound synthesized.

TABLE 4 Sample LiH₂PO₄ Zr(OC₂H₅)₄ V₂O₃ NH₄H₂PO₄ No. 103.93 g/mol 271.41g/mol 149.88 g/mol 115.03 g/mol Li_(a)Zr_(b)V₂PO₄ 1 2.98 mol 0.005 mol 1mol 0.02 mol a = 2.98 b = 0.005 2 2.94 mol  0.01 mol 1 mol 0.06 mol a =2.96 b = 0.01 3  2.9 mol 0.025 mol 1 mol  0.1 mol a = 2.90 b = 0.025 4 2.8 mol  0.05 mol 1 mol  0.2 mol a = 2.80 b = 0.05

EXAMPLE 5

Reaction E—Synthesis of Li_(a)Nb_(b)V₂(PO₄)₃.

LiH₂PO₄+Nb₂O₅+V₂O₃+NH₄H₂PO₄→Li_(a)Nb_(b)V₂(PO₄)₃  (E)

Several compounds having the general formula Li_(a)Nb_(b)V₂(PO₄)₃ weresynthesized per reaction E, per the reaction conditions of Example 1.Table 5 below summarizes the reactants employed and their respectiveamounts for each compound synthesized.

TABLE 5 Sample LiH₂PO₄ Nb₂O₅ V₂O₃ NH₄H₂PO₄ No. 103.93 g/mol 265.81 g/mol149.88 g/mol 115.03 g/mol Li_(a)Nb_(b)V₂(PO₄)₃ 1 2.99 mol 0.001 mol 1mol 0.01 mol a = 2.99 b = 0.002 2 2.98 mol 0.002 mol 1 mol 0.02 mol a =2.98 b = 0.004 3 2.97 mol 0.003 mol 1 mol 0.03 mol a = 2.97 b = 0.006 42.96 mol 0.004 mol 1 mol 0.04 mol a = 2.96 b = 0.008 5 2.95 mol 0.005mol 1 mol 0.05 mol a = 2.95 b = 0.01

EXAMPLE 6

Reaction F—Synthesis of Li_(a)Mg_(b)V₂(PO₄)₃.

LiH₂PO₄+Mg(CH₃CO₂)₂·4H₂O+V₂O₃+NH₄H₂PO₄→Li_(a)Mg_(b)V₂(PO₄)₃  (F)

Several compounds having the general formula Li_(a)Mg_(b)V₂(PO₄)₃ weresynthesized per reaction F, per the reaction conditions of Example 1.Table 6 below summarizes the reactants employed and their respectiveamounts for each compound synthesized.

TABLE 6 Sample LiH₂PO₄ Mg(CH₃CO₂)₂•4H₂O V₂O₃ NH₄H₂PO₄ No. 103.93 g/mol214.46 g/mol 149.88 g/mol 115.03 g/mol Li_(a)Mg_(b)V₂(PO₄)₃ 1 2.98 mol0.01 mol 1 mol 0.02 mol a = 2.98 b = 0.01 2 2.94 mol 0.03 mol 1 mol 0.06mol a = 2.94 b = 0.03 3  2.9 mol 0.05 mol 1 mol  0.1 mol a = 2.90 b =0.05 4  2.8 mol  0.1 mol 1 mol  0.2 mol a = 2.80 b = 0.1

EXAMPLE 7

Reaction G—Synthesis and characterization of Li_(a)Zr_(b)CoPO₄.

LiH₂PO₄+Zr(OC₂H₅)₄+Co₃O₄+NH₄H₂PO₄→Li_(a)Zr_(b)CoPO₄  (G)

Several compounds having the general formula Li_(a)Zr_(b)CoPO₄weresynthesized per reaction G, per the reaction conditions of Example 1.Table 7 below summarizes the reactants employed, and their respectiveamounts, for each compound synthesized.

TABLE 7 Sample LiH₂PO₄ Zr(OC₂H₅)₄ Co₃O₄ NH₄H₂PO₄ No. 103.93 g/mol 271.41g/mol 240.80 g/mol 115.03 g/mol Li_(a)Zr_(b)CoPO₄ 1   1 mol  0.00 mol0.33 mol 0.00 mol a = 1 2 0.98 mol 0.005 mol 0.33 mol 0.02 mol a = 0.98b = 0.005 3 0.96 mol  0.01 mol 0.33 mol 0.04 mol a = 0.96 b = 0.01

EXAMPLE 8

Reaction H—Synthesis of Li_(a)Nb_(b)CoPO₄.

LiH₂PO₄+Nb₂O₅+Co₃O₄+NH₄H₂PO₄→Li_(a)Nb_(b)CoPO₄  (H)

Several compounds having the general formula Li_(a)Nb_(b)CoPO₄ weresynthesized per reaction H, per the reaction conditions of Example 1.Table 8 below summarizes the reactants employed, and their respectiveamounts, for each compound synthesized.

TABLE 8 Sample LiH₂PO₄ Nb₂O₅ Co₃O₄ NH₄H₂PO₄ No. 103.93 g/mol 265.81g/mol 240.80 g/mol 115.03 g/mol Li_(a)Nb_(b)CoPO₄ 1 0.99 mol 0.001 mol0.33 mol 0.01 mol a = 0.99 b = 0.002 2 0.98 mol 0.002 mol 0.33 mol 0.02mol a = 0.98 b = 0.004 3 0.97 mol 0.003 mol 0.33 mol 0.03 mol a = 0.97 b= 0.006 4 0.96 mol 0.004 mol 0.32 mol 0.04 mol a = 0.96 b = 0.008

EXAMPLE 9

Reaction I—Synthesis and characterization of Li_(a)Mg_(b)Co_(c)PO₄.

LiH₂PO₄+Mg(CH₃CO₂)₂·4H₂O+Co₃O₄+NH₄H₂PO₄→Li_(a)Mg_(b)Co_(c)PO₄  (I)

Several compounds having the general formula Li_(a)Mg_(b)Co_(c)PO₄ weresynthesized per reaction I, per the reaction conditions of Example 1.Table 9 below summarizes the reactants employed, and their respectiveamounts, for each compound synthesized.

TABLE 9 Sample LiH₂PO₄ MgCH₃CO₂•4H₂O Co₃O₄ NH₄H₂PO₄ No. 103.93 g/mol214.46 g/mol 240.80 g/mol 115.03 g/mol Li_(a)Mg_(b)Co_(c)PO₄ 1 0.98 mol0.01 mol 0.33 mol 0.02 mol a = 0.98 b = 0.01, c = 1 2 0.96 mol 0.02 mol0.33 mol 0.04 mol a = 0.96 b = 0.02, c = 1 3 0.94 mol 0.03 mol 0.33 mol0.06 mol a = 0.94 b = 0.03, c = 1 4 0.98 mol 0.05 mol 0.33 mol 0.02 mola = 0.98, b = 0.05, c = 0.96

Li_(a)Mg_(b)Co_(c)PO₄ active material synthesized as per Reaction I wasblack in color, and the measured electrical conductivity ranged fromabout 10⁻⁴ S/cm to about 10⁻³ S/cm. LiCoPO₄ active material was brightpurple in color, and the electrical conductivity ranged from about 10⁻⁹S/cm to about 10⁻¹⁰ S/cm.

EXAMPLE 10

Reaction J—Synthesis and characterization of Li_(a)Zr_(b)FePO₄.

LiH₂PO₄+Zr(OC₂H₅)₄+FeC₂O₄·2H₂O+NH₄H₂PO₄→Li_(a)Zr_(b)FePO₄  (J)

Several compounds having the general formula Li_(a)Zr_(b)FePO₄ weresynthesized per reaction J, per the reaction conditions of Example 1.Table 10 below summarizes the reactants employed, and their respectiveamounts, for each compound synthesized.

TABLE 10 Sample LiH₂PO₄ Zr(OC₂H₅)₄ FeC₂O₄•2H₂O NH₄H₂PO₄ No. 103.93 g/mol271.41 g/mol 179.90 g/mol 115.03 g/mol Li_(a)Zr_(b)FePO₄ 1 0.98 mol0.005 mol 1 mol 0.02 mol a = 0.98 b = 0.005 2 0.96 mol  0.01 mol 1 mol0.04 mol a = 0.96 b = 0.01

EXAMPLE 11

Reaction K—Synthesis and characterization of Li_(a)Nb_(b)FePO₄.

LiH₂PO₄+Nb₂O₅+FeC₂O₄·2H₂O+NH₄H₂PO₄→Li_(a)Nb_(b)FePO₄  (K)

Several compounds having the general formula Li_(a)Nb_(b)FePO₄ weresynthesized per reaction K, per the reaction conditions of Example 1.Table 11 below summarizes the reactants employed, and their respectiveamounts, for each compound synthesized.

TABLE 11 Sample LiH₂PO₄ Nb₂O₅ FeC₂O₄•2H₂O NH₄H₂PO₄ No. 103.93 g/mol265.81 g/mol 179.90 g/mol 115.03 g/mol Li_(a)Nb_(b)FePO₄ 1 0.99 mol0.001 mol 1 mol 0.01 mol a = 0.99 b = 0.002 2 0.98 mol 0.002 mol 1 mol0.02 mol a = 0.98 b = 0.004 3 0.97 mol 0.003 mol 1 mol 0.03 mol a = 0.97b = 0.006 4 0.96 mol 0.004 mol 1 mol 0.04 mol a = 0.96 b = 0.008

The weight percent wt% of residual carbon formed upon the decompositionof the Fe reactant complex, was determined to be about 1 to 2 weightpercent wt % for all the samples 1, 2, 3 and 4.

The electrical conductivity for a sample of Li_(0.95)Nb_(0.01)FePO₄ andLi_(0.99)Nb_(0.002)FePO₄ synthesized as per reaction J was determined tobe approximately 10⁻³ S/cm. The measurements were repeated for LiFePO₄prepared per the teachings of Example 11 herein below, which yielded anelectrical conductivity of approximately 10^(—10) S/cm.

EXAMPLE 12

Reaction L—Synthesis and characterization of Li_(a)Mg_(b)Fe_(c)PO₄.

LiH₂PO₄+FeC₂O₄·2H₂O+Mg(CH₃CO₂)₂·4H₂O+NH₄H₂PO₄→Li_(a)Mg_(b)Fe_(c)PO₄  (L)

Several compounds having the general formula Li_(a)Mg_(b)Fe_(c)PO₄ weresynthesized per reaction L, per the reaction conditions of Example 1.Table 12 below summarizes the reactants employed, and their respectiveamounts, for each compound synthesized.

TABLE 12 Sample LiH₂PO₄ Mg(CH₃CO₂)₂•4H₂O FeC₂O₄•2H₂O NH₄H₂PO₄ No. 103.93g/mol 214.46 g/mol 179.90 g/mol 115.03 g/mol Li_(a)Mg_(b)Fe_(c)PO₄ 1   1mol 0.00 mol 1 mol 0.00 mol a = 1 b = 0, c = 1 2 0.98 mol 0.01 mol 1 mol0.02 mol a = 0.98 b = 0.01, c = 1 3   1 mol 0.04 mol 1 mol 0.00 mol a =1, b = 0.04, c = 0.96 4 0.98 mol 0.05 mol 1 mol 0.02 mol a = 0.98, b =0.05, c = 0.96

LiFePO₄ active material synthesized as per Reaction L was green or lightgray in color. In contrast, Li_(a)Mg_(b)Fe_(c)PO₄ active materialssynthesized as per Reaction L were black in color.

Reitveld refined CuKα (λ=1.5405 Å with a scattering angle of 2θ) x-raydiffraction patterns were collected for the LiFePO₄,Li_(0.98)Mg_(0.01)FePO₄, and Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ activematerials, and are represented in FIG. 1. The patterns shown in FIG. 1for Li_(0.98)Mg_(0.01)FePO₄ and Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ show thatthese materials are single phase materials, as is LiFePO₄. Table 13below shows the unit cell dimensions and volumes obtained for the threeactive materials.

TABLE 13 Active Material a (Å) b (Å) c (Å) Volume (Å) LiFePO₄ 10.32456.0088 4.6958 291.3168 Li_(0.98)Mg_(0.01)FePO₄ 10.3158 6.0021 4.6932290.5872 Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ 10.3099 5.9983 4.6920 290.1591

Electrochemical Performance of Active Material:

For several samples identified above, electrochemical cells wereprepared as follows. To test the electrochemical performance of pureactive material and eliminate the effect of carbon and binder, theas-synthesized powder (first passed through 53 micron screen) is wettedwith a suitable volatile solvent (e.g. acetone), sprayed on Al disk andthen pressed under 50,000 pounds per square inch (psi) pressure for 10minutes. The active powder adheres to the Al current collector to form astable disk cathode electrode. There are no carbon additives orpolymeric binder in the disk cathode electrode.

In some of the examples herein below, in order to test theelectrochemical performance of active materials in a regular cellconfiguration, the as-synthesized powder (first passed through 53 micronscreen) is mixed with conductive carbon black (4 wt %) andpoly(vinylidene difluoride) (PVdF) (10 wt %) solution in acetone, andcast onto an Al current collector to form stable film cathode electrode.

Lithium metal foil is employed as the anode. The electrolyte includesethylene carbonate (EC) and ethyl methyl carbonate (EMC) in a weightratio of 2:1, and a 1 molar concentration of LiPF₆ salt. A glass fiberseparator interpenetrated by the solvent and the salt is interposedbetween the cathode and the anode. In each of the examples describedherein, the electrochemical cell is cycled using constant currentcycling at ±0.2 milliamps per square centimeter (mA/cm²) in a range of 3to 5 volts (V) at a temperature of about 23° C., at varying rates.

An electrochemical cell constructed using a disk cathode containingLiCoPO₄ synthesized per the teaching of Example 7 (0% binder, 0% carbon,100% LiCoPO₄ synthesized in a high flow-rate inert atmosphere), wascycled per the conditions stated above. FIG. 2 is a voltage profile(voltage as a function of time) for the cell. As the profile in FIG. 2indicates, the cell exhibited almost no capacity, which is attributed tothe high electrical resistivity of the active material. Anelectrochemical cell constructed using a disk cathode containingLi_(0.98)Mg_(0.05)Co_(0.96)PO₄ (0% binder, 0% carbon) was cycled per theconditions stated above. FIG. 3 is a voltage profile for the cell. Asthe profile in FIG. 3, indicates, LiCoPO₄ doped with Mg exhibited asignificantly greater amount of capacity than undoped LiCoPO₄, even inthe absence of carbon. Table 14 below shows the charge capacity (Q_(c))and discharge capacity (Q_(d)) for the active material contained in eachelectrochemical cell, as well as the corresponding capacity loss foreach cycle.

TABLE 14 Active Material and Cycle Q_(c) Q_(d) Capacity TheoreticalCapacity No. (mAh/g) (mAh/g) Loss (%) LiCoPO₄ 1 1.250 0.162 87.1 166.66mAh/g 2 0.125 0.074 40.5 3 0.055 0.040 27.9 4 0.043 0.030 30.7 5 0.0310.022 29.4 Li_(0.98)Mg_(0.05)Co_(0.96)PO₄ 1 151.0 78.2 48.2 161.3 mAh/g2 77.7 62.4 19.6 3 63.9 51.4 19.6 4 51.8 41.4 20.0 5 39.6 31.8 19.7

An electrochemical cell constructed using a disk cathode containingLiFePO₄ synthesized per the teaching of Example 12 using a highflow-rate inert atmosphere (0% binder, 0% carbon, 100% LiFePO₄), wascycled per the conditions stated above. FIG. 4 is a voltage profile(voltage as a function of time) for the cell. As the profile in FIG. 4indicates, the cell exhibited almost no capacity, which is attributed tothe high electrical resistivity of the active material.

Electrochemical cells constructed using a disk cathode containingLi_(0.98)Mg_(0.01)FePO₄, Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄, andLi_(0.99)Nb_(0.002)FePO₄ (0% binder, 0% carbon) were cycled per theconditions stated above. FIGS. 5, 6 and 7 are voltage profiles for thecells. As the profiles in FIGS. 5, 6 and 7 indicate, LiFePO₄ doped withMg or Nb exhibited a significantly greater amount of capacity thanundoped LiFePO₄, even in the absence of carbon. Table 14 below shows thecharge capacity (Q_(c)) and discharge capacity (Q_(d)) for the activematerial contained in each electrochemical cell, as well as thecorresponding capacity loss for each cycle. As Table 15 indicates,Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ active material (wherein the amount of Feand Li are each dependent (reduced by) the amount of Mg dopant)exhibited superior performance, and high capacity.

TABLE 15 Active Material and Cycle Q_(c) Q_(d) Capacity TheoreticalCapacity No. (mAh/g) (mAh/g) Loss (%) LiFePO₄ 1 0.68 0.00077 99.89 169.9mAh/g 2 0.03 0.00064 97.67 3 0.02 0.00064 96.69 4 0.02 0.00061 96.03 50.01 0.00064 95.68 Li_(0.98)Mg_(0.01)FePO₄ 1 130.35 100.57 22.85 166.4mAh/g 2 107.22 102.56 4.35 3 114.80 102.16 11.01 4 107.36 100.53 6.36 5105.86 99.25 6.24 Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ 1 149.6 148.4 0.9 164.3mAh/g 2 155.6 146.5 5.8 3 159.5 145.5 8.8 4 163.8 144.0 12.1 5 161.6137.0 15.2 Li_(0.98)Nb_(0.002)FePO₄ 1 133.62 98.28 26.45 2 100.18 100.180.00 3 100.80 99.02 1.77 4 100.12 98.65 1.47 5 95.09 93.05 2.15

An electrochemical cell constructed using a disk cathode containingLiFePO₄ synthesized per the teaching of Example 12 using a low flow-rateinert atmosphere, was cycled per the conditions stated above. Thereaction product contained approximately 2.18 wt % residual carbon. FIG.8 is a voltage profile (voltage as a function of time) for the cell. Asthe profile in FIG. 8 indicates, the carbon-containing LiFePO₄ exhibitedenhanced capacity and reduced fade as compared to the carbon-deficientcounterpart.

Electrochemical cells constructed using a disk cathode containingLi_(0.98)Mg_(0.01)FePO₄, LiMg_(0.04)Fe_(0.96)PO₄,Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄, each synthesized per the teachings ofExample 12 using a low flow-rate inert atmosphere, were cycled per theconditions stated above. The reaction products contained approximately1.88 wt %, 2.24 wt % and 1.98 wt % residual carbon, respectively. FIGS.9, 10 and 11 are voltage profiles for the cells. As the profiles inFIGS. 9, 10 and 11 indicate, residual carbon-containing LiFePO₄ dopedwith Mg exhibited a significantly enhanced capacity and reduced fade ascompared to the carbon-deficient counterparts. Table 16 below shows thecharge capacity (Q_(c)) and discharge capacity (Q_(d)) for the activematerial contained in each electrochemical cell, as well as thecorresponding capacity loss for each cycle. As Table 15 indicates,residual carbon-containing Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ activematerial (wherein the amount of Fe and Li are each dependent (reducedby) the amount of Mg dopant) exhibited superior performance, and highcapacity.

TABLE 16 Active Material/C wt %/ Cycle Q_(c) Q_(d) Capacity TheoreticalCapacity No. (mAh/g) (mAh/g) Loss (%) LiFePO₄ 1 156.4 146.9 6.1 (2.18%C) 2 156.4 147.7 5.6 169.9 mAh/g 3 154.1 145.8 5.4 4 150.7 144.6 4.0 5149.9 143.9 4.0 Li_(0.98)Mg_(0.01)FePO₄ 1 155.1 143.5 7.5 1.88% C 2148.5 141.6 4.6 166.4 mAh/g 3 146.0 142.1 2.6 4 146.0 139.9 4.2 5 144.6139.4 3.6 LiMg_(0.04)Fe_(0.96)PO₄ 1 148.1 133.5 9.8 2.24% C 2 135.5130.2 4.0 164.8 mAh/g 3 134.8 130.2 3.4 4 132.9 127.4 4.1 5 129.8 124.34.2 Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ 1 159.2 152.3 4.4 1.98% C 2 156.0153.1 1.8 164.3 mAh/g 3 155.8 151.5 2.8 4 155.8 151.7 2.6 5 154.8 151.32.3

An electrochemical cell constructed using a film cathode containingLi_(0.98)Mg_(0.05)Fe_(0.96)PO₄ (86% active material, 4% carbon, 10%binder) synthesized per the teaching of Example 12 using a highflow-rate inert atmosphere, was cycled per the conditions stated above.The carbon/binder-containing Li_(0.98)Mg_(0.05)Fe_(0.96)PO₄ activematerial exhibited excellent capacity and reduced fade. Table 17 belowshows the average charge capacity (Q_(c)) and discharge capacity (Q_(d))for the active material contained in the five electrochemical cells, aswell as the corresponding capacity loss for each cycle.

TABLE 17 Cycle Q_(c) Q_(d) Capacity No. (mAh/g) (mAh/g) Loss (%) 1 156.9145.1 8.38 2 151.1 144.3 4.5 3 150.1 144.6 3.7 4 149.6 144.8 3.21 5149.6 144.8 2.55 35 152.5 145.7 4.46

The examples and other embodiments described herein are exemplary andnot intended to be limiting in describing the full scope of compositionsand methods of this invention. Equivalent changes, modifications andvariations of specific embodiments, materials, compositions and methodsmay be made within the scope of the present invention, withsubstantially similar results.

1. A battery, comprising: a first electrode comprising a compoundrepresented by the general nominal formula:[A_(a),D_(d)]M_(m)(XY₄)_(p)Z_(e), wherein: (i) A comprises at least onealkali metal, and 0<a≦9; (ii) D is at least one element with a valencestate of ≧2+, and 0<d≦1; (iii) M comprises at least one redox activeelement, M is substituted by a stiochiometric amount of wherebyM+[M_(m-u)D_(v)] wherein u=v and 1≦m≦3; (iv) XY₄ is selected from thegroup consisting of X′[O_(4-x), Y′_(x)], X′[O_(4-y), Y′_(2y)], X″S₄,[X′″_(z), X′_(1-z)]O₄, and mixtures thereof, wherein: (a) X′ and X′″ areeach independently selected from the group consisting of P, As, Sb, Si,Ge, V, S, and mixtures thereof; (b) X″ is selected from the groupconsisting of P, As, Sb, Si, Ge, V, and mixtures thereof; (c) Y′ isselected from the group consisting of a halogen, S, N, and mixturesthereof; and (d) 0≦x≦3, 0≦y≦2, 0≦z≦1, and 1≦p≦3; and (v) Z is selectedfrom the group consisting of OH, a halogen, and mixtures thereof, and0≦e≦4; wherein A, D, M, X, Y, Z, a, d, m, p, e, x, y and z are selectedso as to maintain electroneutrality of the compound; a secondcounter-electrode; and an electrolyte.
 2. The battery of claim 1,wherein A is Li.
 3. The battery of claim 1, wherein D is a transitionmetal.
 4. The battery of claim 3, wherein D is selected from the groupconsisting of Nb, Zr, Ti, Ta, Mo, and W.
 5. The battery of claim 1,wherein D is selected from the group consisting of Mg, Zr and Nb.
 6. Thebattery of claim 1, wherein A is partially substituted by D by isochargesubstitution.
 7. The battery of claim 6, wherein the compound isrepresented by the general nominal formula[A_(a-f),D_(d)]M_(m)(XY₄)_(p)Z_(e), wherein f=d.
 8. The battery of claim6, wherein the compound is represented by the general nominal formula[A_(a-f),D_(d)]M_(m)(XY₄)_(p)Z_(e), wherein f≠d.
 9. The battery of claim1, wherein A is partially substituted by D by aliovalent substitution.10. The battery of claim 9, wherein the compound is represented by thegeneral nominal formula${\lbrack {A_{a - \frac{f}{V^{A}}},D_{\frac{d}{V^{D}}}} \rbrack {M_{m}( {XY}_{4} )}_{p}Z_{e}},$wherein f=d, V^(A) is the oxidation state of A and V^(D) is theoxidation state of D.
 11. The battery of claim 9, wherein the compoundis represented by the general nominal formula${\lbrack {A_{a - \frac{f}{V^{A}}},D_{\frac{d}{V^{D}}}} \rbrack {M_{m}( {XY}_{4} )}_{p}Z_{e}},$wherein f≠d, V^(A) is the oxidation state of A and V^(D) is theoxidation state of D.
 12. The battery of claim 1, wherein M is selectedfrom the group consisting of Ti²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺,Cu²⁺, Mo²⁺, Si²⁺, Sn²⁺, and Pb²⁺.
 13. The battery of claim 1, wherein Mis selected from the group consisting of Ti³⁺, V³⁺, Cr³⁺, Mn³⁺, Fe³⁺,Co³⁺, Ni³⁺, Mo³⁺, and Nb³⁺.
 14. The battery of claim 1, whereinM=MI_(n)MII_(o), 0<o+n≦3 and 0<o,n, wherein MI and MII are eachindependently selected from the group consisting of redox activeelements and non-redox active elements, wherein at least one of MI andMII is redox active.
 15. The battery of claim 1, wherein MI is selectedfrom the group consisting of Ti²⁺, V²⁺, Cr²⁺, Mn²⁺, Fe²⁺, Co²⁺, Ni²⁺,Cu²⁺, Mo²⁺, Si²⁺, Sn²⁺, Pb²⁺, and mixtures thereof and MII is selectedfrom the group consisting of Be²⁺, Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Zn²⁺, Cd²⁺,Ge²⁺, and mixtures thereof.
 16. The battery of claim 1, whereinM=M1_(q)M2_(r), M3_(s), wherein: (a) M1 is a redox active element with a2+ oxidation state; (b) M2 is selected from the group consisting ofredox and non-redox active elements with a 1+ oxidation state; (c) M3 isselected from the group consisting of redox and non-redox activeelements with a 3+ oxidation state; and (d) at least one of p, q and ris greater than 0, and at least one of M1, M2, and M3 is redox active.17. The battery of claim 1, wherein XY₄ is selected from the groupconsisting of PO₄, AsO₄, SbO₄, SiO₄, GeO₄, VO₄, SO₄, and mixturesthereof
 18. The battery of claim 1, wherein p=1.
 19. The battery ofclaim 1, wherein p=3.
 20. The battery of claim 1, wherein XY₄ is PO₄.